Coated granular fertilizers, methods of manufacture thereof, and uses thereof

ABSTRACT

A coated fertilizer comprising a fertilizer granule and a coating disposed on a surface of the fertilizer granule, wherein the coating comprises interpenetrating domains comprising polymer domains and wax domains. A method of making the coated fertilizer is also disclosed.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a 371 of International Application No. PCT/US2016/061486, filed Nov. 11, 2016, which claims priority to U.S. application Ser. No. 62/415,825, filed Nov. 1, 2016 and U.S. application Ser. No. 62/255,669, filed Nov. 16, 2015, all of which are incorporated herein by reference in their entirety.

BACKGROUND

Granular fertilizers can be coated to reduce dust production and to slow the release of nutrients into the soil. To improve fertilizer uptake by the plant, the available fertilizer concentration in the soil should match the plant growth need. Since plants typically follow a sigmoidal growth pattern, the fertilizer availability should be similar to the plant growth rate. Due to various parameters such as soil erosion, volatilization of ammonia, and leaching of nitrates, only about 40% of currently available fertilizers like urea are absorbed by the plant and the remainder is lost to the environment. Hence, there remains a need in the art for improved coated fertilizer which allows for a higher utilization of the fertilizer by the plant.

SUMMARY

Described herein is a coated fertilizer comprising a fertilizer granule and a coating disposed on a surface of the fertilizer granule, wherein the coating comprises interpenetrating domains comprising polymer domains and wax domains.

A process of manufacturing the coated fertilizer comprises at least partially dissolving a polymer and a wax in an organic solvent to form a coating composition; contacting the coating composition with a plurality of fertilizer granules to form at least partially coated fertilizer granules; evaporating the organic solvent from the at least partially coated fertilizer granules to form dried at least partially coated fertilizer granules; and heating the dried at least partially coated fertilizer granules at a temperature effective to at least partially melt the wax to form a coating comprising interpenetrating domains comprising polymer domains and wax domains.

Alternatively, a process of manufacturing the coated fertilizer comprises at least partially dissolving a first structural polymer in a first solvent having a first boiling point to form a first solution; at least partially dissolving a second polymer and a wax in a second solvent having a second boiling point to form a second solution, wherein the second boiling point is different from the first boiling point; contacting the first solution and the second solution with a plurality of fertilizer granules to form at least partially coated fertilizer granules; evaporating the first solvent and the second solvent from the at least partially coated fertilizer granules to form dried at least partially coated fertilizer granules; and heating the dried at least partially coated fertilizer granules at a temperature effective to at least partially melt the wax to form a coating comprising interpenetrating domains comprising polymer domains and wax domains.

The above described and other features are further set forth in the following figures, detailed description, and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The following is a brief description of the drawings wherein like elements are numbered alike and which are presented for the purposes of illustrating the exemplary embodiments disclosed herein and not for the purposes of limiting the same.

FIG. 1A is a scanning electron microscopic image of a sample at 500 times magnification with no pre-treatment.

FIG. 1B is a scanning electron microscopic image of the sample of FIG. 1A at 2000 times magnification with no pre-treatment.

FIG. 2A is a scanning electron microscopic image of a sample at 500 times magnification with 5 hours of pre-treatment.

FIG. 2B is a scanning electron microscopic image of the sample of FIG. 2A at 2000 times magnification with 5 hours of pre-treatment.

FIG. 3A is a scanning electron microscopic image of a sample at 500 times magnification with 10 hours of pre-treatment.

FIG. 3B is a scanning electron microscopic image of the sample of FIG. 3A at 2000 times magnification with 10 hours of pre-treatment.

FIG. 4A is a scanning electron microscopic image of a sample at 500 times magnification with 15 hours of pre-treatment.

FIG. 4B is a scanning electron microscopic image of the sample of FIG. 4A at 2000 times magnification with 15 hours of pre-treatment.

DETAILED DESCRIPTION

The coated fertilizer comprising a fertilizer granule and a coating comprising interpenetrating domains of polymer domains and wax domains has a release rate which more closely matches plant growth rate and as a result has a higher utilization rate than coated fertilizer without the interpenetrating domains. Interpenetrating domains, as used herein, describe domains of different materials which penetrate each other mutually creating a morphology demonstrating distinct domains of separate materials which border one or more domains of a different material. These domains may be irregular in shape. A useful visual analogy is puzzle pieces in which adjoining pieces are domains formed from different materials. Without being bound by theory it is believed that when the polymer is applied it forms a non-continuous coating of polymer domains on the granules and at least some of the gaps in the polymer domains are filled with wax domains when the wax is applied.

The embodiments described herein relate to a coated fertilizer granule. The coating comprises interpenetrating domains of at least one polymer and at least one wax. The fertilizer granule is at least partially coated with a coating that comprises interpenetrating domains of at least one polymer and at least one wax.

It is desirable to improve the mechanical strength of the at least partially coated fertilizer granules. Mechanical strength can affect the ability of the fertilizer granules to withstand the normal handling procedures and can increase the effectiveness of the coating. It has surprisingly been discovered that pre-treating a surface of the fertilizer granule before applying the coating can improve the mechanical properties of the at least partially coated fertilizer granules as well as can improve the adherence of the coating to the fertilizer granule. The pre-treating, among other things, can include smoothing a surface of the fertilizer granule. The pre-treatment can occur after the fertilizer granule has been formed. Coated fertilizers containing a pre-treated fertilizer granule can have a significantly lower percent nitrogen release after 7 days as compared to coated fertilizers not containing a pre-treated fertilizer granule. For example, the pre-treated fertilizer granule can have a percent nitrogen release after 7 days of less than or equal to 70%, for example, less than or equal to 65%, for example, less than or equal to 60%. Pre-treatment can include smoothing of the fertilizer granule surface by pre-heating the granule to a temperature greater than or equal to 90° C. For example, the temperature can be greater than or equal to 100° C., for example, greater than or equal to 105° C., for example, greater than or equal to 125° C. The pre-treatment time can be greater than or equal to 5 hours, for example, greater than or equal to 10 hours, for example, greater than or equal to 15 hours, for example, greater than or equal to 20 hours.

After a coating has been applied (e.g. a 2% coating), the coated fertilizer containing the pre-treated fertilizer granule can be post-treated and weight loss measured. The 2% coating generally refers to a 2% polymer coating by weight. The coating can be applied by the processes described herein and gives a control sample allowing observation of the effect of the pre-treatment. Weight loss can be less for coated fertilizers containing the pre-treated fertilizer granule as compared to coated fertilizers not containing the pre-treated fertilizer granule. Post-treatment can include heating the pre-treated, at least partially coated granules at various temperatures and then measuring percent weight loss. Heating can include temperatures greater than or equal to 50° C., for example, greater than or equal to 60° C., for example, greater than or equal to 70° C., for example, greater than or equal to 80° C., for example, greater than or equal to 90° C., for example, greater than or equal to 100° C. The post-treatment heating time can be greater than or equal to 5 hours, for example, greater than or equal to 10 hours, for example, greater than or equal to 15 hours, for example, greater than or equal to 20 hours. The coated fertilizer containing the pre-treated fertilizer granule can have a percent weight loss of less than or equal to 0.20% after post-treatment, for example, less than or equal to 0.15%, for example, less than or equal to 0.10%.

The fertilizer granules can comprise nitrogen, phosphorus, or potassium sources such as ammonium nitrate, ammonium sulfate, ammonium sulfate nitrate, calcium nitrate, calcium ammonium nitrate, urea, urea-formaldehyde, monoammonium phosphate (“MAP”), diammonium phosphate, polyphosphate compounds, phosphate rock, single superphosphate (“SSP”), triple super phosphate, potassium nitrate, potassium chloride, potassium sulfate (“SOP” or potash), or a combination comprising at least one of the foregoing. In some embodiments, the fertilizer granules comprise urea. The amounts of nitrogen, phosphorus, or potassium sources included in the final fertilizer granules depends on the intended end use, and can be 0 to 60 wt. % for each component, based on the total weight of the fertilizer granule.

Additionally, magnesium sulfate and a source of one or more trace elements, i.e., micronutrients can be included, for example boron, calcium, chlorine, cobalt, copper, iron, manganese, molybdenum, nickel, sodium, zinc, or a combination comprising at least one of the foregoing can be present. These nutrients may be supplied in elemental form or in the form of salts, for example as sulfates, nitrates, or halides. The amount of plant micronutrients depends on the intended end use and can be, for example, 0.1 to 5 weight percent (wt. %), based on the total weight of the fertilizer granule.

Fillers can further be present in the granule, for example bentonite, calcite, calcium oxide, calcium sulfate (anhydrous or hemihydrate), dolomite, talc, sand, or a combination comprising at least one of the foregoing fillers.

Other components of granular fertilizers can include, for example, surfactants, nucleation agents, or recycled fertilizer particles, which can act as a source of nucleating agents, nucleating soil conditioners such as calcium carbonate, activated carbon, elemental sulfur, biocides such as pesticides, herbicides, or fungicides, wicking agents, wetting agents, heat stabilizers, adhesives such as cellulose, polyvinyl alcohols, fats, oils, gum arabics, vinylidene ultraviolet stabilizers, antioxidants, reducing agents, colorants, binders (i.e., organochlorides, zeins, gelatins, chitosan, polyethylene oxide polymers, and acrylamide polymers and copolymers), and the like, as well as combinations comprising at least one of the foregoing.

The fertilizer granules can have any shape or size desired for their intended use. In some embodiments the fertilizer granules are substantially spherical. The fertilizer granules have an average particle diameter of 1.0 to 4.0 millimeters (mm). Within this range the average particle diameter can be greater than or equal to 1.5, or greater than or equal to 2.0 mm. Also within this range the average particle diameter can be less than or equal to 3.5, or less than or equal to 3.0 mm. In some embodiments at least 90% by weight of the fertilizer granules have a particle diameter of 2.0 to 4.0 mm Particle diameter is determined according to “Size Analysis—Sieve Method” IFDC S-107 issued by International Fertilizer Development Center (IFDC) which is the most common and internationally approved method used to determine fertilizer particle size.

The coating on the fertilizer granule comprises interpenetrating domains comprising polymer domains and wax domains. The polymer domains have a rate of biodegradation which differs from the rate of biodegradation of the wax domains when subjected to the same conditions. When the polymer domains comprise two or more polymers, each polymer has a different rate of biodegradation when subjected to the same conditions.

In some embodiments the polymer domains comprise a biopolymer. Exemplary polymers include polysaccharides, polyesters, lignin, and combinations comprising at least one of the foregoing. Exemplary polysaccharides include cellulose acetate, cellulose triacetate, starch acetate, or a combination comprising at least one of the foregoing. Exemplary polyesters include poly(butylene succinate), poly(butylene adipate terephthalate), poly(lactic acid), poly(lactic acid-co-glycolic acid), poly(butylene succinate), poly(caprolactone), poly(glycolide), poly(hydroxybutyrate), poly(hydroxybutyrate-co-hydroxy valerate), or a combination comprising at least one of the foregoing.

The cellulose acetate can have a weight average molecular weight (M_(w)) of 25,000 to 120,000 grams per mol (g/mol), for example, 35,000 to 70,000 g/mol.

The cellulose triacetate can have a M_(w) of 100,000 to 350,000 g/mol, for example, 125,000 to 300,000 g/mol, for example, 200,000 to 275,000 g/mol.

Starch acetate is a starch that has been acetylated to a degree of substitution (DS) of 1 to 3 with an acetyl value of 20% to 70%. As used herein, “acetyl value” refers to the weight percent (wt %) of acetic acid per unit measure of starch acetate. For example, an acetyl value of approximately 62.5 is equivalent to a DS of 3.0.

The poly(butylene succinate) (PBS) can have a M_(w) of 70,000 to 160,000 g/mol. In some embodiments the poly(butylene succinate) can have an M_(w) of 100,000 to 150000 g/mol, for example, 120,000 to 140,000 g/mol. In some embodiments the poly(butylene succinate) can have a M_(w) of 75,000 to 125,000 g/mol, for example, 90,000 to 110,000 g/mol.

The poly(butylene adipate-terephthalate) (ECOFLEX™) can have a weight average molecular weight (M_(w)) of 30,000 to 120,000 g/mol, for example, 50,000 to 100,000 g/mol.

The poly(lactic acid) (PLA) can have a weight average molecular weight (M_(w)) of 30,000 to 250,000 g/mol. The PLA can comprise recycled PLA, scrap PLA or a combination comprising at least one of the foregoing. In some embodiments the poly(lactic acid) can have a M_(w) of 150,000 to 210,000 g/mol, for example, 175,000 to 190,000 g/mol. In some embodiments the poly(lactic acid) can have a M_(w) of 30,000 to 70,000 g/mol, for example, 40,000 to 65,000 g/mol.

The poly(lactic acid-co-glycolic acid) can have a M_(w) of 5,000 to 300,000 g/mol, for example, 10,000 to 250,000 g/mol, for example, 40,000 to 150,000 g/mol.

The poly(caprolactone) can have a M_(w) of 500 to 80,000 g/mol, for example, 5,000 to 70,000 g/mol, for example, 15,000 to 60,000 g/mol.

The poly(glycolide) can have a M_(w) of 500 to 60,000 g/mol, for example, 5,000 to 50,000 g/mol, for example, 20,000 to 40,000 g/mol.

The poly(hydroxybutyrate) can have a M_(w) of 10,000 to 500,000 g/mol, for example, 30,000 to 400,000 g/mol, for example, 75,000 to 350,000 g/mol.

The poly(hydroxybutyrate-co-hydroxy valerate) can have a M_(w) of 10,000 to 600,000 g/mol, for example, 30,000 to 500,000 g/mol, for example, 100,000 to 400,000 g/mol.

Lignin is a polymer of aromatic alcohols most commonly derived from wood. Lignin can be obtained by the Kraft process. Exemplary lignin includes Kraft lignin marketed under the name of INDULIN™ AT or PROTOBIND™ 1000.

In some embodiments, the polymer domains comprise at least two polymers. These polymers may be miscible so as to form a single domain together or may be immiscible and form separate polymer domains.

The coating comprises polymer domains in an amount of 50 to 80 wt %, based on the total weight of the coating.

The wax domains comprise a C₅-C₃₅ wax, polyethylene wax, mineral wax, biobased wax, shellac, or a combination comprising at least one of the foregoing. Waxes are liquid at 110 to 200° F. (43 to 95° C.). Exemplary waxes include natural petroleum waxes, including paraffin waxes (hard, crystalline, brittle waxes composed primarily of unbranched alkanes, typically having melting points of 48 to 70° C.), microcrystalline waxes (soft, amorphous, malleable waxes composed primarily of branched alkanes, typically having melting points of 54 to 95° C.), and fully refined paraffin waxes. Synthetic waxes can also be used, including polyethylene waxes having, for example, a degree of polymerization of 10 to 18 carbon atoms. Exemplary waxes that are commercially available include a petroleum wax, C30+ from Chevron Phillips Chemical (CP-Chem), 7089A, R-4408, and R-3053A available from International Group, Inc.

The coating comprises wax domains in an amount of 20 to 50 wt %, based on the total weight of the coating.

When coated on the fertilizer granules, the amount of the coating is less than or equal to 6 wt. %, for example, 0.1 to 6 wt. %, 0.5 to 5 wt. %, 2 to 5 wt. %, or 3 to 5 wt. %, based on the total weight of the coated fertilizer.

In any of the foregoing embodiments, the coatings can further comprise an adjuvant as known in the art, for example a colorant, an adhesion promoter, or a surfactant, provided that the adjuvant does not significantly adversely affect the desired properties of the coated fertilizer. For example, a surfactant can include a primary and secondary (C₁₆₋₃₀)alkylamine, a (C₁₆₋₃₀)fatty acid amide of a primary (C₁₆₋₃₀)alkylamine, or a (C₁₆₋₃₀)fatty acid ester of a (C₁₆₋₃₀)alkanol. Examples of the foregoing surfactants include cetyl amine, stearyl amine, arachidyl amine, behenyl amine, dicetyl amine, distearyl amine, diarachidyl amine, dibehenyl amine, di(hydrogenated tallow) amine, cetyl stearamide, stearyl stearamide, stearyl erucamide, erucyl erucamide.

Further, in any of the foregoing embodiments, the coating is disposed directly on the granule or other layers, that is, no intervening layers are present other than those described. The coating can be continuous or discontinuous. To optimize the sustained release features of the coated fertilizer, the coating covers 90 to 100% of the surface area of the fertilizer granule.

The thickness of the coating is adjusted to provide the desired sustained release and protection properties. In some embodiments, the total thickness of the coating is 20 to 70 micrometers. For example, the thickness can be greater than or equal to 25, or greater than or equal to 30 micrometers. For example, the thickness can be less than or equal to 65, or less than or equal to 60 micrometers.

A process of manufacturing the coated fertilizer comprises at least partially dissolving a polymer and a wax in an organic solvent to form a coating composition; contacting the coating composition with a plurality of fertilizer granules to form at least partially coated fertilizer granules; evaporating the organic solvent from the at least partially coated fertilizer granules to form dried at least partially coated fertilizer granules; and heating the dried at least partially coated fertilizer granules at a temperature effective to at least partially melt the wax to form a coating comprising interpenetrating domains comprising polymer domains and wax domains. The temperature effective to at least partially melt the wax can be 30° C. to 130° C. Additional wax may be applied during heating. The coating composition may further comprise an additional polymer. It is further contemplated that an additional coating composition may be used to at least partially coat the plurality of fertilizer granules. The additional coating composition may be applied simultaneously or sequentially with the coating composition. The additional coating composition may comprise the same components as the coating composition but in different amounts or the additional coating composition may comprise only a part of the components found in the coating composition. The term “at least partially dissolving” is inclusive of suspending a material in a solvent. It is also inclusive of forming an emulsion.

The process can further include pre-treating the fertilizer granule before the coating is applied. Pre-treating the fertilizer granule can assist in providing greater adherence of the coating to the fertilizer granule and in improving the ability of the coated fertilizer to withstand post formation tests as previously described herein. Pre-treating the fertilizer granule can include smoothing the surface of the fertilizer granule.

Smoothing the plurality of fertilizer granules can be achieved by heating, e.g., heating in a rotating drum or fluid bed. It is further contemplated that mechanical methods such as ball milling could also be used to smooth the plurality of fertilizer granules. In an exemplary method, a plurality of fertilizer granules are heated to a temperature greater than or equal to 90° C. for less than or equal to 15 hours. The temperature can be less than or equal to 110° C. For example, the temperature can be 90° C. to 100° C., or 100° C. to 110° C. The time can be 1 hour to 5 hours, or 5 hours to 15 hours. The fertilizer granules can be heated in an oven, a forced air oven, disc dryer, paddle dryer, rotary dryer, conveyor dryer, fluid bed dryer, or a combination comprising at least one of the foregoing. Optionally, the fertilizer granules can be cooled before coating.

Contacting the coating composition with a plurality of fertilizer granules can be achieved by spray coating (for example, top, bottom, or side spray coating), drum coating, pan coating, fluid bed coating, continuous pour coating, or any other method known to those of skill in the art. This coating can be done in a batch or in a continuous process. The granules can be coated with a single layer in a single coating application, or the granules can be coated with multiple layers of the same coating material, such as, 2, 3, 4, 5, or more layers. Evaporating and heating the at least partially coated fertilizer granules can occur in the same step or in sequential steps. Exemplary devices include a rotary evaporator, an oven, or the like.

Exemplary organic solvents include chloroform, toluene, methylene chloride, or a combination comprising one or more of the foregoing.

Alternatively, a process of manufacturing the coated fertilizer comprises at least partially dissolving a first polymer in a first solvent having a first boiling point to form a first solution; at least partially dissolving a second polymer and a wax in a second solvent having a second boiling point to form a second solution, wherein the second boiling point is different from the first boiling point; contacting the first solution and the second solution with a plurality of fertilizer granules to form at least partially coated fertilizer granules; evaporating the first solvent and the second solvent from the at least partially coated fertilizer granules to form dried at least partially coated fertilizer granules; and heating the dried at least partially coated fertilizer granules at a temperature effective to at least partially melt the wax to form a coating comprising interpenetrating domains comprising polymer domains and wax domains. The temperature effective to at least partially melt the wax is in the range of 30° C. to 130° C. Additional wax may be applied during heating. Contacting the coating composition with a plurality of fertilizer granules can be achieved by spray coating (for example, top, bottom, or side spray coating), drum coating, pan coating, fluid bed coating, continuous pour coating, or any other method known to those of skill in the art. This coating can be done in a batch or in a continuous process. The granules can be coated with a single layer in a single coating application, or the granules can be coated with multiple layers of the same coating material, such as, 2, 3, 4, 5, or more layers. Evaporating and heating the at least partially coated fertilizer granules can occur in the same step or in sequential steps. Exemplary devices include a rotary evaporator, an oven, or the like.

The process can further include pre-treating the fertilizer granule before the first solution and the second solution are contacted with the fertilizer granule. Pre-treating the fertilizer granule can assist in providing greater adherence of the first solution and/or the second solution to the fertilizer granule and in improving the ability of the coated fertilizer to withstand post formation tests as previously described herein. Pre-treating the fertilizer granule can include smoothing the surface of the fertilizer granule.

It is also contemplated that the coated fertilizer described herein may be mixed with uncoated fertilizer granules or with a coated fertilizer having a coating comprising a polymer but free of wax.

In use, the coated fertilizer is applied to the locus of a plant or seed, in particular the soil of a plant or seed to be fertilized.

The coated fertilizers having sustained release properties are further illustrated by the following non-limiting examples.

EXAMPLES Example 1

The materials used in Example 1 are described in Table 1.

TABLE 1 Component Chemical Description Source PBS A Poly(butylene succinate) 18127 Danimer PBS B Poly(butylene succinate) 1020MD Showa Denko PLA Poly(lactic acid) 2003D Natureworks C30+ Alpha-olefin wax Chevron Phillips Chloroform Aldrich Methylene Aldrich Chloride Toluene Aldrich General Procedures

Urea granulation. In urea granulation, seed particles, or recycled urea prills, are rotated through a central agglomeration tube via a high velocity air stream. A spray nozzle at the bottom of the agglomeration tube sprays urea melt onto the particles. Because the urea melt droplets are supplied at high velocities with air constantly passing through the granulator, the seeds are wetted and dried efficiently. As more urea melt is supplied by the spray nozzles, the urea particles grow in diameter and the process is concluded when the desired size has been achieved.

Preparation of coating formulations. Coating solutions were made using the formulations shown in Table 2 and Table 3. In Tables 2 and 3, “g” is the abbreviation for grams.

Coating procedure. The coating solutions were applied to the fertilizer granules using an air atomized spray in a rotating drum. For the examples in Table 2 additional C30+ wax was melted and applied to the partially coated particles using a rotary evaporator rotating at 20-30 revolutions per minute (rpm) in an oil bath. For the examples in Table 3, all the wax was applied using the solutions which were applied using an air atomized spray. The examples in Table 3 were further subjected to thermal conditioning using either a rotary evaporator at a temperature of 95-101° C. for 20 minutes, or maintained in a 70° C. oven for 1 or 2 hours.

Urea release test. The test is used to mimic a release profile of urea at given time intervals. The time intervals that samples were taken and analyzed were 24 hours, 7 days, and 14 days. 5 grams of coated granules were placed in 95 grams of deionized water at room temperature for the specified time period. The water was analyzed for nitrogen content at the end of the time period, measured in percent. The urea release test gives information allowing for a calculation of how much urea is no longer bound by the coating. In Table 2, in Sample 1, 31.8% of the initial amount of coated urea used in the test has been released in 7 days. Stated another way Sample 1 demonstrates that about 70% of the urea was still entrapped by the coating (after 7 days) and gradually diffusing.

TABLE 2 24 h N 7 day N 14 day N Sample # Solution 1 Solution 2 Rotovap release release release 1 9 g PBS A, 21 g 21 g PBS A, 9 g 0.25 g 5.3 31.8 — PLA, in 900 g PLA, 30 g C30+, in C30+ methylene 900 g methylene chloride chloride 2 9 g PBS B, 21 g 21 g PBS B, 9 g 0.37 g 0 11.9 — PLA, in 900 g PLA, 22.5 C30+, C30+ methylene in 900 g methylene chloride chloride 3 9 g PBS A, 21 g 21 g PBS A, 9 g 0.37 g 0.52 3.17 7.92 PLA, in 720 g PLA, 22.5 g C30+, C30+ methylene in 650 g methylene chloride and chloride, 250 g 180 g toluene toluene 4 9 g PBS A, 21 g 21 g PBS A, 9 g  0.5 g 0.13 1.0 — PLA, in 720 g PLA, 15 g C30+, in C30+ methylene 650 g methylene chloride, 180 g chloride, 250 g toluene toluene 5 9 g PBS A, 21 g 21 g PBS A, 9 g 0.37 g 0.06 1.38 4.09 PLA, in 720 g PLA, 22.5 g C30+, C30+ methylene in 650 g methylene chloride, 180 g chloride, 250 g toluene toluene

TABLE 3 24 h N 24 h N release release 24 h N after after 24 h N release oven at oven at release before after 70° C. for 70° C. for Sample # Solution 1 Solution 2 conditioning Rotovap 1 hour 2 hours 6 9 g PBS A, 9 g PBS A, 43.5 37.4 17.9 5.98 21 g PLA, 21 g PLA, 15 g C30+, 30 g C30+, in 900 g in 900 g methylene methylene chloride chloride 7 12 g PBS A, 12 g PBS A, 35.6 — 23.7 19.95 18 g PLA, 18 g PLA, 15 g C30+, 30 g C30+, in 900 g in 900 g methylene methylene chloride chloride 8 15 g PBS A, 15 g PBS A, 29.81 — 19.92 11.91 15 g PLA, 15 g PLA, 15 g C30+, 30 g C30+, in 900 g in 900 g methylene methylene chloride chloride

Table 2 shows that a mixed solvent approach improved the quality of coating significantly resulting in a much slower release. Examples 3-5 show slower nitrogen release than Examples 1 and 2. Without being bound by theory, it is believed that the mixture containing various boiling point solvents helped in keeping the solution coating more uniform before evaporation. Further, it was also discovered that by thermal conditioning of the granule having a coating containing wax along with the polymer results in an improved (i.e., slower) release rate (Table 3). Without wishing to be bound by theory, this is due to the wax in the interpenetrating domains flowing due to thermal conditioning thus sealing the polymer from defects such as pinholes, cracks, etc. Wax within the coating as opposed to outside the coating (overcoat) also likely increases the hydrophobicity of the coating layer, thus reducing water permeability.

Example 2

The materials used in Example 2 are described in Table 4.

TABLE 4 Component Chemical Description Source PBS Poly(butylene succinate) 1020MD Showa Denko PLA Poly(lactic acid) 2003D Natureworks Chloroform Aldrich Toluene Aldrich Urea Granular SABIC

Formulations for the coatings are shown in Table 5.

TABLE 5 Solution 1 Solution 2 PLA PBS Chloroform Toluene PLA PBS Chloroform Toluene Sample # (g) (g) (g) (g) (g) (g) (g) (g) 9 21 9 630 270 9 21 630 270 10 21 9 630 270 9 21 630 270 11 21 9 450 450 9 21 450 450 12 21 9 450 450 9 21 450 450 13 21 9 0 900 9 21 0 900 14 21 9 450 450 9 21 450 450 15 21 9 450 450 9 21 450 450 16 21 9 450 450 9 21 450 450 17 21 9 450 450 9 21 450 450 18 21 9 450 450 9 21 450 450 19 21 9 450 450 9 21 450 450 20 21 9 450 450 9 21 450 450 21 21 9 450 450 9 21 450 450 22 21 9 450 450 9 21 450 450 23 21 9 450 450 9 21 450 450 24 21 9 450 450 9 21 450 450 25 21 9 450 450 9 21 450 450 26 21 9 450 450 9 21 450 450 27 21 9 450 450 9 21 450 450 28 21 9 450 450 9 21 450 450 29 21 9 450 450 9 21 450 450

The fertilizer granules were placed in a stainless steel pan, which was then placed in a forced-air convection oven set to a temperature of 90-110° C. for up to 15 hours. At different time intervals up to 15 hours, a small aliquot of approximately 5 grams of urea was collected and SEM images taken. FIGS. 1A-4B show the differences in the surface after pre-heating. After the urea was in the oven for a given time frame, the urea was then spray coated in a rotating drum with biopolymers that were dissolved in organic solvents. The solvent was evaporated, leaving behind the coating material on the surface of the fertilizer granule. Once the coating was deposited, the samples were again placed in a stainless steel pan and placed in a forced-air convection oven that is set to 70-90° C. for up to 15 hours to remove residual solvent that remains on the coated fertilizer granule. After a given time frame, approximately 5 grams of the coated fertilizer granule was placed in 95 grams of deionized water at room temperature (19-25° C.) and the percent nitrogen (% N) release was measured using a refractometer after 24 hours.

Additional samples from each batch were tested for abrasion resistance. The abrasion resistance tests consisted of placing a number of equally sized stainless steel balls and 100 mL of the coated fertilizer into a stainless steel drum having equally spaced flights. The drum was closed and then rotated at 30 revolutions per minute for 5 minutes. After 5 minutes, the stainless steel balls were separated from the coated fertilizer using a sieve at which point approximately 5 grams of the abraded coated urea was placed in 95 grams of deionized water at room temperature and the % N release was measured using a refractometer after 24 hours. Although described herein with respect to a force-air convection oven, other devices can be used, including, but not limited to, disc dryers, drum dryers, paddle dryers, rotary dryers, conveyor dryers, and/or fluid bed dryers.

Table 6 shows the % N release for before and after the abrasion test along with the pre- and post-heat treatment. Temperatures are listed in ° C. and time in hours.

TABLE 6 1-Day % N Release Post- Before After Before Pre-Heat Pre-Heat Post- Heat Abrasion Abrasion and After Sample # T Time Heat T Time Test Test Δ 9 None 0 70 15 21.06 55.49 34.43 10 None 0 70 15 28.04 51.13 23.09 11 None 0 70 15 16.12 40.23 24.11 12 None 0 70 15 11.31 25.31 14.00 13 None 0 70 15 29.47 67.62 38.15 17 None 0 70 15 19.39 65.93 46.54 18 None 0 70 15 22.94 62.35 39.41 19 105 15 70 15 12.85 20.21 7.36 20 105 15 70 15 16.04 20.12 4.08 21 105 15 70 15 6.11 8.09 1.98 22 105 15 70 15 29.88 27.11 −2.77 23 105 15 70 15 19.18 24.02 4.84 24 105 15 70 15 15.15 19.52 4.37 25 105 15 70 15 28.08 26.59 −1.49

As can be seen in FIGS. 1A-4B, the pre-treatment of a surface of the fertilizer granule provides a smoother surface of the fertilizer granule. FIGS. 1A, 2A, 3A, and 4 are at 500 times magnification, while FIGS. 1B, 2B, 3B, and 4B are at 2,000 times magnification. FIGS. 1A and 1B are the control sample with no pre-treatment. FIGS. 2A and 2B are a sample after pre-heating for 5 hours. FIGS. 3A and 3B are the sample in FIGS. 2A and 2B after pre-heating for 10 hours. FIGS. 4A and 4B are the sample in FIGS. 2A and 2B after pre-heating for 15 hours. As can be seen in the figures, a smoother surface is achieved with the longer heating. FIGS. 1A-4B further demonstrate that the surface morphology of the fertilizer granule undergoes transformation after it is heated in the forced-air convection oven. The sample in FIGS. 1A and 1B, which was not treated with heat, does not have a smooth surface compared to the samples that were heated for a period of time in FIGS. 2A-4B.

This transformation also appears to affect the % N release observed after the abrasion test after 34 hours as shown in Table 6. The % N release between the before abrasion and after abrasion test varies between 14.00% and 46.54% for samples that were not pre-heated. The % N release difference between samples that were pre-heated varies from no change to 7.36%.

The samples in Table 7 were also measured for % N release after 7 days and the percent weight loss after post-heat treatment.

TABLE 7 Pre-Heat Pre-Heat % N Release Post-Heat Post-Heat % Wt. Sample # T Time 1 day 7 days T Time Loss 14 None 0 21.36 81.62 70 15 0.40 15 None 0 18.90 77.00 70 15 0.37 16 None 0 19.78 79.09 70 15 0.24 26 105 15 25.87 69.00 70 15 0.06 27 105 15 18.58 69.29 70 15 0.10 28 105 15 13.55 65.18 70 15 0.10 29 105 15 17.86 56.26 70 15 0.06

As shown in Table 7, the samples that were pre-heated had a significantly lower % N release after 7 days as compared to the non-pre-heated samples. Furthermore, the post-heated (i.e., dried) samples which contained the pre-heated fertilizer granules after a 2% coating was applied had a significantly lower % weight loss as compared to the post-heated samples without the pre-heated fertilizer granule.

Embodiment 1: A coated fertilizer, comprising: a fertilizer granule; and a coating disposed on a surface of the fertilizer granule, wherein the coating comprises interpenetrating domains comprising polymer domains and wax domains.

Embodiment 2: The coated fertilizer of Embodiment 1, wherein the fertilizer granule comprises urea.

Embodiment 3: The coated fertilizer of Embodiment 1 or Embodiment 2, wherein the fertilizer granule is a pre-treated fertilizer granule having improved adherence properties to the coating.

Embodiment 4: The coated fertilizer of any of Embodiments 1-3, wherein the pre-treated fertilizer granule comprises a smoothed surface.

Embodiment 5: The coated fertilizer of any of Embodiments 1-4, wherein the polymer domains comprise at least two polymers.

Embodiment 6: The coated fertilizer of any of Embodiments 1-5, wherein the polymer domains comprise a biopolymer.

Embodiment 7: The coated fertilizer of Embodiment 6, wherein the biopolymer is a polysaccharide, a polyester, lignin or a combination comprising at least one of the foregoing.

Embodiment 8: The coated fertilizer of any of Embodiments 1-7, wherein the wax domains comprise a C₅-C₃₅ wax.

Embodiment 9: The coated fertilizer of any of Embodiments 1-8, wherein the polymer domains have a first rate of biodegradation and the wax domains have a second rate of biodegradation that differs from the first rate under the same conditions.

Embodiment 10: The coated fertilizer of Embodiment 9, wherein the polymer domains comprise at least two polymers, each having a different rate of biodegradation under the same conditions.

Embodiment 11: The coated fertilizer of any of Embodiments 3-10, wherein the pre-treated fertilizer granule has a percent nitrogen release after 7 days of less than or equal to 70%, preferably, less than or equal to 65%, more preferably, less than or equal to 60%.

Embodiment 12: A process of manufacturing the coated fertilizer of any of Embodiments 1-11, comprising: at least partially dissolving a polymer and a wax in an organic solvent to form a coating composition; contacting the coating composition with a plurality of fertilizer granules to form at least partially coated fertilizer granules; evaporating the organic solvent from the at least partially coated fertilizer granules to form dried at least partially coated fertilizer granules; and heating the dried at least partially coated fertilizer granules at a temperature effective to at least partially melt the wax to form a coating comprising interpenetrating domains comprising polymer domains and wax domains.

Embodiment 13: The process of Embodiment 12, wherein the coating composition further comprises an additional polymer.

Embodiment 14: The process of Embodiment 12 or Embodiment 13, further comprising forming an additional coating composition free of wax comprising the polymers and organic solvent of the coating composition and wherein the plurality of fertilizer granules is also contacted with the additional coating composition prior to evaporating the organic solvent.

Embodiment 15: The process of Embodiment 14, wherein the coating composition and the additional coating composition comprise the polymers in differing amounts.

Embodiment 16: The process of Embodiment 13, further comprising forming an additional coating composition having the same components as the coating composition and the wax is present in the additional coating composition in an amount different from the coating composition and wherein the plurality of fertilizer granules is also contacted with the additional coating composition prior to evaporating the organic solvent.

Embodiment 17: The process of any of Embodiments 12-16, further comprising applying additional wax while heating the dried at least partially coated fertilizer granules at a temperature effective to at least partially melt the wax.

Embodiment 18: The process of any of Embodiments 12-17, wherein the organic solvent comprises a combination comprising at least two organic solvents, each having a different boiling point.

Embodiment 19: The process of any of Embodiments 12-18, wherein the organic solvent comprises chloroform, toluene, methylene chloride, or a combination comprising at least one of the foregoing.

Embodiment 20: A process of manufacturing the coated fertilizer of any of Embodiments 1-11, comprising: at least partially dissolving a first structural polymer in a first solvent having a first boiling point to form a first solution; at least partially dissolving a second polymer and a wax in a second solvent having a second boiling point to form a second solution, wherein the second boiling point is different from the first boiling point; contacting the first solution and the second solution with a plurality of fertilizer granules to form at least partially coated fertilizer granules; evaporating the first solvent and the second solvent from the at least partially coated fertilizer granules to form dried at least partially coated fertilizer granules; and heating the dried at least partially coated fertilizer granules at a temperature effective to at least partially melt the wax to form a coating comprising interpenetrating domains comprising polymer domains and wax domains.

Embodiment 21: The process of any of Embodiments 12-20, wherein the temperature effective to at least partially melt the wax is 30 ° C. to 130° C.

Embodiment 22: The process of any of Embodiment 12-21, further comprising using a rotating drum to contact the coating on the fertilizer granule.

Embodiment 23: The process of any of Embodiments 12-22, further comprising adding additional amounts of wax during heating the dried at least partially coated fertilizer granules.

Embodiment 24: The process of any of Embodiments 12-23, further comprising pre-treating the fertilizer granule by heating to a temperature greater than or equal to 90° C., for a time period of greater than or equal to 5 hours.

The singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. “Or” means “and/or.” The endpoints of all ranges directed to the same component or property are inclusive and independently combinable. The suffix “(s)” as used herein is intended to include both the singular and the plural of the term that it modifies, thereby including at least one of that term (e.g., “colorant(s)” includes at least one colorant). “Optional” or “optionally” means that the subsequently described event or circumstance can or cannot occur, and that the description includes instances where the event occurs and instances where it does not. Unless defined otherwise, technical and scientific terms used herein have the same meaning as is commonly understood by one of skill in the art to which this invention belongs. Substantially as described herein generally refers to greater than or equal to 75%, for example, greater than or equal to 75%, for example, greater than or equal to 95%.

As used herein, a “combination” is inclusive of blends, mixtures, alloys, reaction products, and the like. Compounds are described using standard nomenclature. For example, any position not substituted by any indicated group is understood to have its valency filled by a bond as indicated, or a hydrogen atom. A dash (“-”) that is not between two letters or symbols is used to indicate a point of attachment for a substituent. For example, —CHO is attached through carbon of the carbonyl group.

All references cited herein are incorporated by reference in their entirety. While typical embodiments have been set forth for the purpose of illustration, the foregoing descriptions should not be deemed to be a limitation on the scope herein. Accordingly, various modifications, adaptations, and alternatives can occur to one skilled in the art without departing from the spirit and scope herein. 

What is claimed is:
 1. A coated fertilizer, comprising: a fertilizer granule; and a coating disposed on a surface of the fertilizer granule, wherein the coating comprises interpenetrating domains comprising polymer domains and wax domains.
 2. The coated fertilizer of claim 1, wherein the fertilizer granule comprises urea.
 3. The coated fertilizer of claim 1, wherein the fertilizer granule is a pre-treated fertilizer granule having improved adherence properties to the coating.
 4. The coated fertilizer of claim 3, wherein the pre-treated fertilizer granule comprises a smoothed surface.
 5. The coated fertilizer of claim 1, wherein the polymer domains comprise at least two polymers.
 6. The coated fertilizer of claim 1, wherein the polymer domains comprise a biopolymer.
 7. The coated fertilizer of claim 1, wherein the wax domains comprise a C₅-C₃₅ wax.
 8. The coated fertilizer of claim 1, wherein the polymer domains have a first rate of biodegradation and the wax domains have a second rate of biodegradation that differs from the first rate under the same conditions.
 9. The coated fertilizer of claim 8, wherein the polymer domains comprise at least two polymers, each having a different rate of biodegradation under the same conditions.
 10. The coated fertilizer of claim 3, wherein the pre-treated fertilizer granule has a percent nitrogen release after 7 days of less than or equal to 70%.
 11. A process of manufacturing a coated fertilizer comprising a fertilizer granule and a coating disposed on a surface of the fertilizer granule, wherein the coating comprises interpenetrating domains comprising polymer domains and wax domains, the process comprising: at least partially dissolving a polymer and a wax in an organic solvent to form a coating composition; contacting the coating composition with a fertilizer granule to form an at least partially coated fertilizer granule; evaporating the organic solvent from the at least partially coated fertilizer granule to form a dried at least partially coated fertilizer granule; and heating the dried at least partially coated fertilizer granule at a temperature effective to at least partially melt the wax to form a coating comprising interpenetrating domains comprising polymer domains and wax domains.
 12. The process of claim 11, wherein the coating composition further comprises an additional polymer.
 13. The process of claim 12, further comprising forming an additional coating composition free of wax comprising the polymers and organic solvent of the coating composition and wherein the fertilizer granule is also contacted with the additional coating composition prior to evaporating the organic solvent, wherein the coating composition and the additional coating composition comprise the polymers in differing amounts.
 14. The process of claim 12, further comprising forming an additional coating composition having the same components as the coating composition and the wax is present in the additional coating composition in an amount different from the coating composition and wherein the fertilizer granule is also contacted with the additional coating composition prior to evaporating the organic solvent.
 15. The process of claim 11 further comprising applying additional wax while heating the dried at least partially coated fertilizer granule at a temperature effective to at least partially melt the wax.
 16. The process of claim 11, wherein the temperature effective to at least partially melt the wax is 30° C. to 130° C.
 17. The process of claim 11, further comprising using a rotating drum to contact the coating on the fertilizer granule.
 18. The process of claim 11, further comprising adding additional amounts of wax during heating the dried at least partially coated fertilizer granule.
 19. The process of claim 11, further comprising pre-treating the fertilizer granule by heating to a temperature greater than or equal to 90° C., for a time period of greater than or equal to 5 hours.
 20. A process of manufacturing a coated fertilizer comprising a fertilizer granule and a coating disposed on a surface of the fertilizer granule, wherein the coating comprises interpenetrating domains comprising polymer domains and wax domains, the process comprising: at least partially dissolving a first structural polymer in a first solvent having a first boiling point to form a first solution; at least partially dissolving a second polymer and a wax in a second solvent having a second boiling point to form a second solution, wherein the second boiling point is different from the first boiling point; contacting the first solution and the second solution with a fertilizer granule to form an at least partially coated fertilizer granule; evaporating the first solvent and the second solvent from the at least partially coated fertilizer granule to form a dried at least partially coated fertilizer granule; and heating the dried at least partially coated fertilizer granule at a temperature effective to at least partially melt the wax to form a coating comprising interpenetrating domains comprising polymer domains and wax domains. 